Case study of introducing non-processed products: Request for resolution of confusion from an automotive parts manufacturer.
Achieve up to 3 times the number of shots! Improve the tool life of punches with variability!
During a recent visit to a car parts manufacturer we have been working with, we discovered a large quantity of used punches. A 200L drum was filled with used punches measuring Φ8×27mm. Upon discussing the situation, they expressed concern about the unstable quality of the punches they are currently purchasing, which leads to variability in tool life and makes it difficult to calculate the timing for replacements. We promptly introduced them to our punch designer and conveyed the challenges faced on-site. Although the designer was initially at a loss, they explained a rough outline of a proposed solution based on their previous experience with custom machining, which led to the response, "Please go ahead with Bandai!" When we proposed an improvement plan using metal film coating to keep costs down, they replied, "We have tried that before, but it resulted in early breakage." From that information, we hypothesized that the heat generated during the coating process might be the cause and began to take measures. As a result, the previously unstable punch usage increased to an average of 15,000 shots, achieving a stable tool life that is approximately three times longer. *For more details, please refer to the PDF document or feel free to contact us.
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【Request Details】 ■Product Name: Punch for Pin Clamping ■Current Situation: The replacement cycle for the punch, which is a consumable tool, is unstable at 5,000 to 10,000 shots, making it difficult to calculate the timing for replacement, causing confusion. Although the cause has been investigated, no clear answer has been found. ■Issue: Achieving stable long life for the punch by improving wear resistance, abrasion resistance, and chipping resistance. 【Summary】 In punch manufacturing, the important tip is usually finished by grinding. While wire cutting allows for efficient finishing, the heat generated can compromise the hardness of the tip. However, in cases like this one, where parts are frequently replaced, grinding is not suitable due to the labor and cost involved. Therefore, to achieve mass production through wire cutting while avoiding thermal effects during metal coating, the decision was made to select "SKD11 high-temperature tempered material" as the base material. *For more details, please refer to the PDF document or feel free to contact us.
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For more details, please refer to the PDF document or feel free to contact us.
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The concerns faced in the daily procurement of custom-made processed products, such as "not arriving on time," "unstable quality," "unable to process according to the drawings," and "existing suppliers going out of business," among others. Bandaï's proud custom processing procurement network, the "Hometown Processing Network," consists of unique processing companies from various regions including Hyogo, Osaka, Shimane, Tottori, Hiroshima, Aichi, Kanagawa, and Ibaraki, and it leads to solutions for a wide range of issues related to custom-made processed products. Additionally, in recent years, we have also established a procurement network with reliable overseas processing companies, the "International Processing Network," to strengthen our ability to resolve cost-related concerns.